CN113841300A

CN113841300A - Plug contact, semi-finished product for producing a plug contact element and method for producing the plug contact element

Info

Publication number: CN113841300A
Application number: CN202080036754.6A
Authority: CN
Inventors: M·埃克施泰因; C·迪林; U·卡布林格; P·帕尔
Original assignee: Amphenol Tuchel Electronics GmbH
Current assignee: Amphenol Tuchel Electronics GmbH
Priority date: 2019-05-17
Filing date: 2020-05-14
Publication date: 2021-12-24
Also published as: WO2020234104A1; US20220209432A1; DE102019113152B3; EP3970239A1; JP2022532653A

Abstract

The invention relates to a plug contact element (100) for producing an electrically conductive connection, comprising a crimp section for producing an electrically conductive connection to a line and at least one plug contact mandrel (90) for producing a releasable electrically conductive connection to a contact box (70), wherein the plug contact element (100) is of one-piece design and the plug contact mandrel (90) comprises an at least partially inner tongue (91) which is at least partially surrounded by a contact blade outer region (92) so that a sandwich fold of the plug contact mandrel (90) is formed at least partially, said sandwich fold having an at least two-layer material structure. The invention further relates to an arcuate semi-finished product (100') for producing a plug contact element (100) according to the invention and to a method for producing a plug contact element.

Description

Plug contact, semi-finished product for producing a plug contact element and method for producing the plug contact element

Technical Field

The invention relates to a plug contact element for producing an electrically conductive connection, comprising a crimp section for producing an electrically conductive connection to a line and at least one plug contact mandrel for producing a releasable electrically conductive connection to a contact box. The invention also relates to an arc-shaped or plate-shaped semifinished product for producing a plug contact element according to the invention and to a method for producing a plug contact element.

Background

Electrical contact elements, contact arrangements, pluggable and releasable cable connection elements and production methods suitable for this are available in the known prior art. The socket contact element or the plug contact element can be designed as a crimp contact. In connection technology for electrical contact tasks, crimp contacts are designed as elements with webs, the web ends of which are bent around the electrical conductor and are simultaneously pressed against it. This available joining technique is called crimping. The deformation and pressing processes required for this purpose are usually applied to a semifinished product prepared for this purpose, which is present as uncrimped or previously crimped starting material and forms the subsequent contact element. To achieve crimping, the semi-finished product is often placed on an anvil of a crimping tool. Subsequently, the electrical conductor or the stripped section of the electrical conductor is placed on the contact element. The at least one crimping tab is then bent around the stripped section and pressed against it in order to establish a mechanically stable and electrically conductive contact between the contact element and the electrical conductor.

Depending on the field of application, different, partially increasing requirements are placed on the crimped connection. Example (c): mechanical strength, fatigue strength, low resistance electrical energy transmission, corrosion resistance, gas tightness and liquid tightness.

In addition to the crimped contact, by its functional task, stopping a lead, a cable or a similar (in most cases current-carrying) line on the contact element, a large number of other requirements are placed on the contact member. For this reason, in addition to the crimped connection region, further body-like components are present inside the contact element, which components are realized integrally or separately. Examples of this are clamping and guiding elements, bushings, connectors, plug contacts, etc.

Known methods for producing the contact element are in particular stamping and deformation processes. First, the flat piece is separated from the bent piece of sheet material or the bent material by a stamping step or more generally also by a separation step. The flat part is provided with a contour in a suitable manner, which is shaped for the contact element and its defined function support. The flat semifinished product provided in this way is subsequently further formed in one or more deformation steps. Possible deformation processes can be achieved by folding, crimping, pressing, deep drawing, etc.

Other manufacturing possibilities of the contact element can be realized by sintering processes, additive manufacturing methods or by cutting or cutting machining.

The combination of the methods of stamping and deformation of flat raw material, although in an economical and reliable manner for providing contact elements in large quantities, limits the integration of different functions into one-piece contact elements and in particular socket contact elements due to the limited geometry.

In order to alleviate this disadvantage, the functions of the integrated implementation are limited or reduced, in order to reduce the complexity of the components and/or to implement the contact components in multiple pieces. Additive manufacturing methods such as 3D printing or stereolithography may also be considered, however these methods are only limitedly suitable for mass production, are economically disadvantageous and are limited in terms of processable substances.

The subject matter of DE 102017126185 a1 is an invention whose basic idea consists of a contact element with an elastic clamping element, wherein the clamping element has a securing arm which surrounds the contact element and a clamping spring arm for contacting a litz wire conductor. In this way, a contact element with a plug contact section is realized, which is designed in two parts for the combined function of the litz wire conductor contact and the releasable plug contact.

The known plug contact elements have disadvantages which may include, inter alia, economic manufacture, plug safety and/or contact safety, mechanical strength, structural integrity, fatigue strength, impact resistance and/or vibration resistance, corrosion resistance, electrical conductivity properties, and which cannot be met or are not fully met.

Disclosure of Invention

The object of the invention is to at least partially reduce the above-mentioned disadvantages and to provide a one-piece plug contact element.

In order to solve the problem, the invention proposes a plug contact element for producing an electrically conductive connection, which is of one-piece design and is equipped with a crimp section for producing an electrically conductive connection to a line and a plug contact, a contact blade, a plug contact mandrel for producing a releasable electrically conductive connection to a contact housing. The invention also relates to a curved semi-finished product for producing a plug contact element and to a method for producing the same by deformation.

The invention recognizes that the geometric complexity and/or the deformation sequence of the flat material as a semi-finished product for a one-piece plug contact element is suitable for at least partially reducing the disadvantages present in the prior art and furthermore provides further advantages.

The invention proposes that, starting from a curved flat material with an edge geometry adapted to the plug contact element, the contact design is produced preferably by deformation such that in the plug-in region, i.e. in the region of the plug contact, the contact blade, the plug contact mandrel, the result of the folding of the sandwich layer is sufficient for the plug contact cross section to have three times the material thickness after folding.

According to the invention, the cavity formed on the inside by the contact knife geometry is filled or occupied by the tongues, so that the outer material of the plug contact mandrel is supported on the inside. Triple material thickness and/or support significantly improves strength.

The inner tongue element and the outer contact blade region and the crimp section or the section for fixing the conductor are integral parts of the plug contact element. This results in a construction situation which represents a double connection of the plug contact spindle to the contact box. The first connection is made via the contact blade outer region and the second connection is made via the tongue element. This double connection also achieves a high stability of the structure and of the contact knife.

Preferably, the invention provides that symmetrical folds and symmetrical cross sections are formed in the region of the contact knives. This means that the tongue axis is surrounded symmetrically or point symmetrically by the contact knife outer region. The abutment of the outer material here preferably lies in the plane of symmetry. Different designs than in the case of symmetrical geometries are likewise supported by the invention.

In addition to at least partially reducing the disadvantages present in the prior art, the teachings in accordance with the present invention provide a number of advantages:

this structure supports the one-piece design of the plug contact element, so that this can be produced by a plate, curved flat material with the outer edge geometry according to the invention. In addition, the advantage of reasonable and suitable mass production is obtained.

The plug contact element is embodied in a sandwich-like folded manner, so that the strength of the plug contact element as well as the strength of the overall component is increased by the triple or two-layer or/and three-layer material structure. The double connection of the contact blade to the plug contact element significantly increases the strength and the structural integrity.

The outer material of the plug contact mandrel is folded around the inner tongue element, so that very small corner radii can be formed in the region of the beads. In this way, the invention supports an enlarged face of flat form with a plug contact mandrel, preferably quadrangular in cross section, which serves as a contact face. The result is an increased contact surface, which improves the contact quality for the electrically conductive connection.

Another advantage of the geometrically designed according to the invention is its scalability within narrow tolerances in size, shape and position and/or reproducibility with high accuracy. This ensures the highest quality requirements and meets strict safety regulations.

Drawings

The invention is explained in detail below with the aid of preferred embodiments in conjunction with the drawing.

In the drawings:

fig. 1a, 1b show perspective views of an exemplary embodiment of a plug contact element and an enlarged illustration of the plug contact region;

fig. 2a, 2b show a top view and a bottom view of an exemplary embodiment of a plug contact element and an end side view thereof;

fig. 3a, 3b show further perspective views of an exemplary embodiment of a plug contact element and an enlarged illustration of the plug contact region;

fig. 4 shows a top view of a possible embodiment of an arc-shaped, one-piece flat material as a semi-finished product for the plug contact element after a profiled manufacturing step, for example a stamping process, and before deformation by crimping and folding.

Detailed Description

Fig. 1a shows a perspective view of an exemplary embodiment of a plug contact element 100 with its different sections 10 to 60 and a contact blade 90 which is fastened to a contact box 70 by a connecting section 80. The main elements of the plug contact mandrel 90 are an inner tongue 91 and a contact blade outer region 92.

Fig. 1b shows an enlarged illustration of a plug contact region 90 with a contact box 70, which are coupled to one another by a connecting section 80. The contact blade 90 with its main part tongue 91 and outer region 92 and its connecting section 80 (formed by its respective connecting webs 81, 82) are constructed in one piece on the basis of a semi-finished flat piece 100'.

The tab 91, which is arranged on the inside and in this embodiment centrally, is enclosed or surrounded by the blade outer region 92. The tongue 91 has a quadrangular or rectangular cross section. Other cross-sections, such as oval, circular, egg-shaped, triangular, are contemplated. Sections other than square sections can be produced by solid deformation (hot or cold), forging or cutting based on the semi-finished flat piece 100'. In the longitudinal direction L of the flap 91, this flap is surrounded by a contact-knife outer region 92, wherein at least one seam, abutment 93 is formed by a preferably realized folding process. The interface 93 may be implemented with or without an air gap.

The contact blade outer region 92 may have a radius, chamfer 94 on at least one longitudinal edge and/or be deformed by a crimping process. On the end side, a chamfer or a point 95 can optionally be provided to assist the penetration into the counterpart of the plug contact 90. The tip 95 can be designed flush with the enclosed tongue 91 on the end side or can also be designed to be recessed and to protrude with respect to the tongue 91.

Fig. 2a shows a top view and a bottom view of an exemplary embodiment of a plug contact element 100 with a connection section 80 for a plug contact spindle 90. An end view of the plug contact element 100 is shown in fig. 2 b. The tab connection tab 81 of this embodiment is embodied as waist-shaped, i.e. a tab width which decreases in the longitudinal extension direction L towards the contact knife 90. The tabs may also be arranged to be constant in width in the longitudinal direction L. The projecting region of the tab connection tab 81 on the contact box 70 and/or on the tab element 91 can be formed in a soft arc, for example by a radius, in order to reduce the notch effect locally.

As shown, the connecting web 82 of the contact blade outer region can likewise be kidney-shaped and spatially curved in such a way that it is shaped not only parallel to the plane of the projection on the contact box 70 but also out of this plane. Preferably, the invention provides that the connecting webs 82 of the contact-knife outer region are designed at the contact box 70 partially around their outer contour and/or partially around in the connecting region to the contact-knife outer region 92. In this way, the structure according to the invention achieves a special design strength and bending strength in this connection region, which is increased again by the interaction of the tongue connection tab 81.

Fig. 3a shows an exemplary embodiment of a plug contact element 100 in two perspective views with different spatial orientations from one another. The longitudinal extension of the plug contact mandrel 90 is in this example substantially equal to the longitudinal extension of the contact box 70. Other length designs are possible and supported by the invention, depending on the required plugging depth of the contact blade 90 into the plug contact fitting, the plug contact bushing.

The plug contact region 90, which is shown three-dimensionally and enlarged in relation to fig. 3a, with the connecting section 80, is the subject matter of fig. 3 b. The connecting webs 82 of the partially circumferential contact blade outer region at the contact box 70 and the contact blade outer region 92 are illustrated in their three-dimensional extent. The contact mandrel tip 95 may be designed at least partially as a rounding R.

Fig. 4 shows a top view of a possible embodiment of an arched, one-piece flat material 100' as a semi-finished product for the plug contact element 100 after a profiled manufacturing step, for example a stamping process, and before deformation by crimping or folding.

The subsequent contact blade 90 is integrally connected by its element tongue 91 and contact blade outer region 92 to the contact box material 70 via the connecting region 80 or the

webs

81, 82.

The geometric design of this example provides that the contact blade outer region 92 is designed in an offset manner with respect to the longitudinal axis L. This offset and the distance from the tongue 91 achieved in the transverse direction with respect to the longitudinal axis L together with the length of the edge to be formed of the contact box 70 determine the type of enclosure of the contact-knife outer region 92 of the wrapping tongue 91. The variant shown supports a symmetrical folding of the docking 93 according to fig. 1 to 3.

In the case of an eccentric abutment 93, a U-shaped enclosure or other geometric folding, a change in shape and a change in position are required in relation to the connection region 80, the stop position of the

webs

81, 82, the width ratio of the

contact knife elements

91, 92 and the contact box edge length.

The deformation process for designing the plug contact element 100 can be roughly divided into four regions of the semi-finished flat piece 100':

a central region MB therebetween, and

-the two outer regions adjoining the central region, and

centering of the tongue 91, and

-surrounding the tongue by the contact blade outer area.

The central region MB is not deformed or only edge-deformed in the operating region 10 and in the region contacting the cassette 70, so that a substantially planar structure is obtained. In other regions, spherical or spatially different forms of deformation, for example cylindrical segment-shaped, are realized.

The corresponding outer region can be a crimping measure, a folding process or a freely deformable object. In particular, a crimping sequence and a folding sequence can be provided in the region of the contact box 70.

After at least substantially performing the deformation process of the zones and regions 10 to 70 of the semi-finished product 100', the

plug contact regions

80, 90 are shaped:

a. centering of the tongue 91 is performed by: bringing the tongue 91 parallel to the longitudinal axis L at least close to the central axis M in case of deformation of the tongue element connection tab 81;

b. the tongue 91 is surrounded by a contact blade outer region 92.

Step b may be supplemented by: the centering required for centering the contact blade outer region 92 with respect to the proximity to the center of the tongue 91 is performed by deformation of the connecting tab 82 of the contact blade outer region.

List of reference numerals

10 operating section

20 first connection section

30 insulating section

40 second connection section

50 crimp section

60 third connecting section

70 contact case, contact case material

80 connector section of a plug contact element

81 tongue, tongue element connection tab

82 contact blade outer region connecting tab

90 plug contact, contact blade, plug contact spindle, plug contact area

91 tongue and tongue element

92 contact blade outer zone

93 joint, butt joint part, and butt joint part of plug contact mandrel

94 radius, chamfer, and crimp zone

95 bevel, tip, contact mandrel tip

100 plug contact element

100' semi-finished flat piece

L longitudinal axis

M center axis

R round part and round part

MB center area.

Claims

1. A plug contact element (100) for producing an electrically conductive connection, having a crimp section (50) for producing an electrically conductive connection to a line and having at least one plug contact mandrel (90) for producing a releasable electrically conductive connection to a contact box (70), characterized in that the plug contact element (100) is of one-piece design and the plug contact mandrel (90) has an at least partially inner tongue (91) which is at least partially surrounded by the contact blade outer region (92) so that a sandwich fold of the plug contact mandrel (90) with an at least two-layer material structure is formed at least partially.

2. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterised in that the material structure is three-layered.

3. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterised in that the plug contact mandrel (90) and/or the tongue (91) have a substantially square cross section.

4. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterised in that the contact blade outer region (92) has a counter-contact (93) which is embodied centrally or eccentrically and is provided with or without a counter-contact gap.

5. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterized in that a connection section (80) is provided, which has at least one connection tab (81) for the tongue (91) and at least one connection tab (82) for the contact blade outer region (92).

6. Plug contact element (100) for producing an electrically conductive connection according to claim 5, characterised in that at least one connection tab (81, 82) is kidney-shaped.

7. Plug contact element (100) for producing an electrically conductive connection according to claim 5, characterised in that the at least one connection tab (82) for the outer region of the contact blade is spatially curved.

8. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterized in that the contact blade outer region (92) has a radius, a chamfer (94) and/or is deformed by a crimping process at least one longitudinal edge.

9. Plug contact element (100) for producing an electrically conductive connection according to claim 1, characterised in that the contact blade (90) is shaped with a tip (95) and/or has a rounded portion R on the insertion-side end face.

10. Plug contact element (100) for producing an electrically conductive connection according to claim 9, characterised in that the tip (95) is designed flush with the enclosed tongue (91) on the end side or is recessed or protrudes with respect to the tongue (91).

11. Curved semifinished product (100') for producing a plug contact element (100) according to one of the preceding claims, characterized in that the semifinished material is electrically conductive and deformable, so that a plug contact element (100) of one-piece construction with a plug contact mandrel (90) can be produced by crimping and/or folding and/or spatially deforming.

12. Curved semifinished product (100 ') for producing a plug contact element (100) according to claim 11, wherein the edges and contours of the semifinished product (100') support the geometry of the plug contact element (100) and its plug contact mandrel (90) after deformation.

13. Curved semifinished product (100 ') for producing a plug contact element (100) according to claim 12, wherein the edges and contours of the semifinished product (100') have at least one tongue (91) and at least one contact-blade outer region (92), which are coupled to the contact box (70) by means of a connecting section (80).

14. Method for producing a plug contact element (100) according to one of claims 1 to 10 from a semifinished product (100') according to one of claims 11 to 13 by spatial deformation and/or folding and/or crimping, characterized in that the contact blade (90) is shaped after the deformation of the regions and regions (10 to 70) by forming an enclosure of the tongue (91) by the contact blade outer region (92).

15. Method for producing a plug contact element (100) according to claim 14, characterised in that the tongue (91) is centred before the enclosure is formed in that: the tongue (91) is brought at least close to the central axis M parallel to the longitudinal axis L in the event of deformation of the tongue element connection tab (81).